differential ISUZU TFS SERIES 1997 Owner's Guide

4B-62 REAR AXLE
4. POWER NOT BEING TRANSMITTED TO THE WHEELS
(PROPELLER SHAFT OPERATION IS NORMAL)
Checkpoint Trouble Cause Countermeasure
Replace the rear axle shaftBroken rear axle shaft NG
Replace the drive pinion and
the ring gear as a setDrive pinion and ring gearBroken drive pinion and/or ring
gear
Replace the differential gears
and/or the spiderDifferential cage gearsBroken differential cage gears
and/or spider NG NG
OK OK
Rear axle shaft

4B-64 REAR AXLE
ITEM NO. ILLUSTRATION PART NO. PART NAME
RAL-34
9-8522-1272-0
(J-24254)Axle case oil seal installer
(for 194mm)
RAL-41
5-8840-0275-0
(J-37264) Differential holding fixture
RAL-40
5-8840-0003-0
(J-3289-20) Holding fixture base
RAL-44
5-8840-0013-0
(J-22888) Side bearing puller
RAL-9
9-8521-1743-0
(J-8107-2)Side bearing plug adapter
(for 194mm)
RAL-10
5-8840-2196-0
(J-8107-4)Side bearing plug adapter
(for 220mm)
RAL-50
5-8840-0133-0
(J-8614-01)Pinion flange holder
(for 194mm)
RAL-51
5-8840-2157-0
(J-37211)Pinion flange holder
(for 220mm)
RAL-539-8521-5032-0 Final pinion spindle

FRONT WHEEL DRIVE 4C1-1
SECTION 4C1
FRONT WHEEL DRIVE
TABLE OF CONTENTS
PAGE
Main Data and Specifications ...................................<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[ 4C1- 3
Special Parts Fixing Nuts and Bolts ............................................................................. 4C1- 4
Recommended Liquid Gasket ....................................................................................... 4C1- 7
Recommended Thread Locking Agents ....................................................................... 4C1- 7
Servicing<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011[<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[..... 4C1- 8
General Description........................................................................................................ 4C1-9
Front Drive Axle Assembly............................................................................................ 4C1-12
Removal and Installation .......................................<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011[ 4C1-12
Disassembly <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011[<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011001100110011[ 4C1-15
Inspection and Repair................................................................................................ 4C1-18
Reassembly <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011001100110011[ 4C1-19
Differential ....................................................................................................................... 4C1-22
Disassembly <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011[<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011001100110011[ 4C1-22
Major Components ............................................................................................... 4C1-22
Minor Components............................................................................................... 4C1-25
Inspection and Repair................................................................................................ 4C1-27
Reassembly <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011001100110011[ 4C1-29
Minor Components............................................................................................... 4C1-29
Major Components ............................................................................................... 4C1-31
Front Hub and Disc (4
2 Model) .................................................................................... 4C1-41
Disassembly <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011[<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011001100110011[ 4C1-41
Inspection and Repair................................................................................................ 4C1-44
Reassembly <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011001100110011[ 4C1-45
Front Hub and Disc (4
4 Model) .................................................................................... 4C1-48
Disassembly <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011[<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011001100110011[ 4C1-48
Inspection and Repair................................................................................................ 4C1-50
Reassembly <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011001100110011[ 4C1-51
Front Hub and Disc (Automatic Locking Hub) ............................................................. 4C1-54
INDEX

FRONT WHEEL DRIVE 4C1-3
MAIN DATA AND SPECIFICATIONS
FRONT AXLE AND DIFFERENTIAL
Ring gear size mm(in) 167 (6.6) 194 (7.6)
Axle tube
Type It consists of the duce, a cast iron housing and the Axle tube.
Gear type Hypoid
Gear ratio (to 1)
HEC.2.0L engine - -
HEC.2.2L engine 4.555 4.777
Differential type Two pinion
Oil capacity liter 1.0 1.4
(US/UK gal.) (0.26/0.22) (0.4/0.33)
Axle shaft type Constant velocity joint (Birfield joint type and double offset joint).
Hub locking type Automatic locking and Manual locking free wheel hubs.
FRONT PROPELLER SHAFT
Transmission type MSG MUA
Outside diameter mm(in) 40 (1.57) 40 (1.57)
Inside diameter mm(in) 33 (1.30) 32 (1.26)
Length mm(in) 505 (19.88) 471 (18.54)
(between two spiders center)

FRONT WHEEL DRIVE 4C1-5
FRONT DIFFERENTIAL
Nm (kgfm/lbft)
25.55 (2.60.5/18.83.6) 167mm 147-294 (15-30/109-217)
194mm 176.6-274.7 (18-28/130-202)
68.7
4.9 (7.00.5/50.63.6) 167mm 78.5
9.8 (81/57.97.2)
194mm 107.9
9.8 (111/79.57.2)167mm 68.7
9.8 (71/50.67.2)
194mm 98.1
9.8 (101/72.37.2)

FRONT WHEEL DRIVE 4C1-15
DISASSEMBLY
Disassembly Steps
1. Band
2. Bellows
3. Circlip
4. BJ shaft assembly
5. Ball
6. Snap ring
7. Ball retainer
8. Ball guide
9. Band
10. Bellows
11. Dust seal12. BJ shaft
13. Bolt
14. DOJ case assembly
15. Snap ring
16. Bearing
17. Snap ring
18. O-ring
19. Oil seal
20. Bracket
21. DOJ case
22. Axle case and differential

FRONT WHEEL DRIVE 4C1-19
REASSEMBLY
Reassembly Steps
1. Axle case and differential
2. DOJ case
3. Bracket
4. Oil seal
5. O-ring
6. Snap ring
7. Bearing
8. Snap ring
9. DOJ case assembly
10. Bolt
11. BJ shaft12. Dust seal
13. Bellows
14. Band
15. Ball guide
16. Ball retainer
17. Snap ring
18. Ball
19. BJ shaft assembly
20. Circlip
21. Bellows
22. Band

4C1-22 FRONT WHEEL DRIVE
DIFFERENTIAL
DISASSEMBLY
MAJOR COMPONENTS
Disassembly Steps
1. Bolt
2. Differential assembly
3. Axle case
4. Bolt
5. Bearing cap
6. Diff. cage assembly
7. Side bearing outer race
8. Side bearing
9. Adjust shims
10. Flange nut
11. Flange12. Dust cover
13. Pinion gear
14. Inner bearing
15. Adjust shim
16. Collapsible spacer
17. Inner bearing outer race
18. Oil seal
19. Outer bearing
20. Outer bearing outer race
21. Diff. carrier

FRONT WHEEL DRIVE 4C1-23
Important Operations
5. Bearing Cap
Apply a setting mark to the side bearing cap and the differential
carrier.
7. Side Bearing Outer Race
After removal, keep the right and left hand side bearing
assemblies separate to maintain inner and outer race
combinations.
8. Side Bearing
Remover : 5-8840-0013-0
(J-22888)
Adapter : 5-8521-0019-0 167 mm)
9-8521-1743-0 (194 mm)
(J-8107-2)
9. Adjust Shims
Note the thickness and position of the shims removed.
10.Flange Nut
Holding wrench : 5-8840-0133-0 (167 mm and 194 mm)
(J-8614-01)
13.Pinion Gear
Remove the drive pinion assembly using a soft metal rod and a
hammer.
Spindle : 9-8521-5032-0

FRONT WHEEL DRIVE 4C1-25
MINOR COMPONENTS
Disassembly Steps
1. Bolt
2. Ring gear
3. Lock pin
4. Cross pin5. Pinion gear
6. Side gear
7. Thrust washer
8. Differential cage